Quarter Scale

A quarter scale model was planned on being made before the actual plug was constructed.  This was to let us have some practice in laying down bondo,

laying down fiberglass and peeling it off.  It was made by using print outs of a solid works model made up from the CMM, 12 sections were printed off and traced

then a strong cardboard was cut out from this and positioned together. 

After the foam was added, this is how far it expanded too.

The first layer of foam added and shaved down to meet the contours.

This is the result after bondo was laid down and sanded, this is one of many layers.

Next primer and paint was layed down so that a smooth surface could be created that wax could be put on. 

The final result

This is the mold that resulted from the quarter scale plug.  Here we are testing how the mold release will work and practicing

vacuum bagging to get used to the process.

Sand bags were layed down since the first vacuum bag process failed due to not having all air holes sealed well enough.